ABB central inverters

Hardware manual
PVS800-MWS megawatt stations
 Hardware manual
PVS800-MWS megawatt stations

Table of contents

1. Safety instructions

5. Mechanical installation

6. Electrical installation

8. Start-up

2012 ABB Oy. All Rights Reserved. 3AUA0000092830 Rev B

EN
EFFECTIVE: 2012-11-23
 5

Table of contents

1. Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safe installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Working areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety instructions for the switchgear compartment . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety instructions for the transformer compartment . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety instructions for the inverter compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2. Introduction to this manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3. Hardware description
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4. Storing, lifting and transporting

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Place the substation higher than the surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Construct a sturdy foundation for the substation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Construct an earthing electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Finalize the surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Foundation option 1 Supporting the substation with gravel . . . . . . . . . . . . . . . . . . . . . 31
6

Foundation option 2 Supporting the substation with concrete beams . . . . . . . . . . . . 32

Foundation option 3 Supporting the substation with concrete pipes . . . . . . . . . . . . . 33
Placing the substation on the foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6. Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Locations of the cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Earthing (grounding) the substation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Protective earthing (grounding) inside the substation . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Measuring the insulation resistances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connecting the cabling from the solar generator to the inverters . . . . . . . . . . . . . . . . . 37
Connecting the control cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Connecting the power grid cabling to the switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7. Finalizing and checking the installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Finalizing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Landscaping the substation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Checking the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8. Start-up
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Tools needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Start-up tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Pre-checking the switchgear (voltage not connected) . . . . . . . . . . . . . . . . . . . . . . . 42
Pre-checking the transformer (voltage not connected) . . . . . . . . . . . . . . . . . . . . . . . 42
Pre-checking the inverters (voltage not connected) . . . . . . . . . . . . . . . . . . . . . . . . . 42
Connecting the substation to the solar power generator and commissioning the inverters
42
Connecting the substation to the power grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Connecting the inverters to AC supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

9. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Inverter compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cleaning the inverter compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Replacing the intake air filters of the inverter compartment . . . . . . . . . . . . . . . . . . . 47
Replacing the stirrer fan in the inverter compartment . . . . . . . . . . . . . . . . . . . . . . . . 48
Replacing the UPS battery (option +G413) in the inverter compartment . . . . . . . . . 48
Transformer and switchgear compartments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cleaning the transformer and switchgear compartments . . . . . . . . . . . . . . . . . . . . . 49
Cleaning the intake air filters on the doors of transformer compartment . . . . . . . . . 49
Replacing the intake air filters on the doors of transformer compartment . . . . . . . . . 50
Replacing the cooling fan in the switchgear compartment . . . . . . . . . . . . . . . . . . . . 51
Substation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking and repairing the painted surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
 7

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking and repairing the non-painted, zinc coated surfaces . . . . . . . . . . . . . . . . . 53
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checking and cleaning the grounding bars and points . . . . . . . . . . . . . . . . . . . . . . . . 54
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

10. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Ratings: Input data (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Ratings: Output data (AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Auxiliary power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Power cable lead-through and terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Paint colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Degree of protection and ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fuses and protection relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Product compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Cable lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

11. Drawings
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Dimensions, layout, transportation details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Lifting drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Location of cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Further information
8
 Safety instructions 9

1
Safety instructions

Contents of this chapter

This chapter represents the use of warnings in the manual and instructs in safe
installation, start-up, use and maintenance of the PVS800-MWS substation.

Use of warnings
Warnings caution you about conditions which can result in serious injury or death and/or
damage to the equipment, and advise on how to avoid the danger. The following warning
symbols are used in this manual:

Electricity warning warns of hazards from electricity which can cause physical
injury and/or damage to the equipment.

General warning warns about conditions, other than those caused by electricity
which can result in physical injury and/or damage to the equipment.
10 Safety instructions

Safe installation, start-up and maintenance

This section contains the safety instructions which you must follow when installing,
commissioning and maintaining the substation. If ignored, physical injury or death may
follow, or damage may occur to the equipment.
Only authorized electricians are allowed to install, start-up and maintain the substation.
Working methods, tools, components etc. must follow the IEC regulations.
Always follow the local safety regulations concerning the substations.
PVS800-MWS is a medium voltage device. Before you are allowed to work in the medium
voltage (switchgear and transformer) compartments, you must receive the task-specific
instructions from the on-site foreperson in charge of the electrical installation work. The
general instructions given in this manual never substitute the compulsory task specific
instructions.
If others must be close by while the doors are opened, warn them, and if required, provide
supervision and guidance.

General safety instructions

WARNING! Before any work, repeat the seven steps safety precautions
described below.

1. Clearly identify the work location.

Read the safety instructions of the work area and the component you are working on.
See the subsections below and component-specific manuals.
2. Disconnect and secure against reconnection.
Disconnect all possible power supplies. Lock the disconnectors to open position and
attach a warning notice to them. After disconnection of the inverters, always wait for 5
minutes to let the intermediate circuit capacitors to discharge.
3. Protect against any other live parts.
4. Take special precautions when close to bare conductors.
5. Check the installation is dead.
Always ensure by measuring that there is no voltage connected.
6. Carry out earthing (grounding) and short circuiting.
7. Issue a permit to work.

Working areas
The substation is divided in to three working areas based on the precautions needed for
safe working: switchgear compartment, transformer compartment and inverter
compartment. There are separate safety instructions for each of these compartments.
 Safety instructions 11

Safety instructions for the switchgear compartment

WARNING! Perform the procedure below before starting the work on the
switchgear. Ignoring the instructions can cause physical injury or death, or
damage to the equipment.
1. Identify the switchgear and read its safety instructions.
Check the operation of the capacitive voltage indicators in all switchgear bays (all
phase LEDs are switched on when voltage is connected).
2. Disconnect the switchgear from all possible power supplies (grid, solar generator and
parallel connected substations), and secure by locking and tagging.
i. Stop the inverters. Open the DC disconnecting switches [Q2] in both inverter units
([PVS1] and [PVS2]), lock and add a warning notices.
ii. Open the AC disconnecting switches [Q1] in both inverters units ([PVS1] and
[PVS2]), lock and add a warning notices.
iii. Switch off auxiliary power to both inverters.
iv. Open the breaker or fuse switch on the transformer side of the switchgear.
v. Turn the disconnecting switch on the transformer side of the switchgear (if any) to
open position. Lock and add warning notice.
vi. Disconnect the switchgear terminals from all possible external power supplies
(grid and parallel substations). See the user's manual of the feeding device. Lock
and add warning notices.
3. Check that all shrouds/screens are on place.
4. Check that you will not be near any live parts while working. Disconnect the live
circuits or protect with shrouds/screens.
5. Check that the switchgear is dead.
i. Check the status of the voltage indicators in all switchgear bays (all phase LEDs
which were on at step 1 are now switched off).
6. Earth the switchgear and inverters.
i. Turn the earthing switches of the switchgear to earthed position, lock and add
warning notices. If the substation is connected to parallel substations, make sure
that you also turn the appropriate earthing switches to earthed position.
ii. Temporary ground the switchgear terminals at all possible external power supplies
(grid and parallel substations). See the user's manual of the feeding device. Lock
and add warning notices.
iii. Temporary ground the inverter ([PVS1] and [PVS2]) AC sides with appropriate
temporary grounding set.
7. Issue a work permit.
12 Safety instructions

Safety instructions for the transformer compartment

WARNING! Perform the procedure below before starting the work on the
transformer. Ignoring the instructions can cause physical injury or death, or
damage to the equipment.
1. Identify the transformer and read its safety instructions.
2. Disconnect the transformer from both possible power supplies (switchgear and solar
generator), and secure by locking, earthing and tagging.
i. Stop the inverters. Open the DC disconnecting switches [Q2] in both inverters
units ([PVS1] and [PVS2]), lock and add a warning notices.
ii. Open the AC disconnecting switches [Q1] in both inverters units ([PVS1] and
[PVS2]), lock and add a warning notices.
iii. Switch off auxiliary power to both inverters.
iv. Open the breaker on the transformer side of the switchgear.
v. Turn the disconnecting switch on the transformer side of the switchgear (if any) to
open position. Lock and add warning notice.
3. Check that all shrouds/screens are on place.
4. Check that you will not be near any live parts while working. Disconnect the live
circuits or protect with shrouds/screens.
5. Check that the transformer is dead (high voltage terminals, low voltage terminals, any
auxiliary power and instrumentation). Use an appropriate high voltage tester only for
the high voltage side, and multimeter with suitable testing heads for the low voltage
side.
6. Earth the transformer side of the switchgear and inverters.
i. Temporary ground the inverter ([PVS1] and [PVS2]) AC sides with appropriate
temporary grounding set.
ii. Turn the earthing switch on the transformer side of the switchgear to earthed
position, lock and equip it with a warning notice.
7. Issue a work permit.
 Safety instructions 13

Safety instructions for the inverter compartment

WARNING! Perform the procedure below before starting the work on the
inverters. Ignoring the instructions can cause physical injury or death, or damage
to the equipment.
1. Identify the inverter which you need to work on. Read the inverter safety instructions.
2. Disconnect the inverter from both possible power supplies (transformer and solar
generator), and secure by locking and tagging.
i. Stop the inverters. Open the DC disconnecting switches [Q2] in both inverters
units ([PVS1] and [PVS2]), lock and add a warning notices.
ii. Open the AC disconnecting switch [Q1] of the appropriate inverter unit ([PVS1] or
[PVS2]), lock and add a warning notice. After disconnection of the inverter, always
wait for 5 minutes to let the intermediate circuit capacitors to discharge.
iii. Switch off auxiliary power to both inverters.
iv. Open the breaker on the transformer side of the switchgear.
v. Turn the disconnecting switch at the transformer side of the switchgear (if any) to
open position. Lock and add warning notice.
vi. Disconnect all inverter DC supplies. The DC disconnectors are usually located in
the junction boxes on the solar field. Lock and add warning notices.
3. Check that all shrouds/screens are on place except the one that prevent access to the
parts that you must work on currently.
4. Check that you will not be near any live parts while working. Disconnect the live
circuits or protect with shrouds/screens.
5. Check that the circuit is dead: AC and DC terminals of the inverters and other
accessible parts in the main circuit. Use a multimeter with suitable testing heads.
6. Temporary ground the inverter.
i. Temporary ground the inverter ([PVS1] or [PVS2]) AC and DC sides with
appropriate temporary grounding set.
7. Issue a work permit.
14 Safety instructions

Safe operation
This section contains the safety instructions which you must follow when operating the
substation. If ignored, physical injury or death may follow, or damage may occur to the
equipment.

WARNING! Keep all doors of the substation locked while the substation is
operating. Allow access to the keys of each compartment to the authorized
personnel only.
 Introduction to this manual 15

2
Introduction to this manual

Contents of this chapter

This chapter gives information on the manual such as applicability, audience and contents.
It also lists the related documents.

Applicability
The manual is applicable with the PVS800-MWS substations.

Target audience
This manual is intended for persons who transport, store, plan the installation, install,
commission and maintain the PVS800-MWS substation.
Read the manual before working on the substation. You are expected to know the
fundamentals of electricity, wiring, electrical components and electrical schematic
symbols.
The manual is written for readers worldwide.

Contents of the manual

Safety instructions
Introduction to this manual
Hardware description
Storing, lifting and transporting
Mechanical installation
Electrical installation
16 Introduction to this manual

Start-up
Finalizing and checking the installation
Maintenance
Technical data
Drawings

Related documents
Document Applicability

Manuals

PVS800-MWS substation hardware manual Whole substation

(3AUA0000092830 [English])

PVS800-57 hardware manual (3AUA0000053689 Inverters

[English])

PVS800 central inverters firmware manual Inverters

(3AUA0000058422 [English])

Instructions manual for dry-type transformers Transformer

(1LES100001-YB)
OR
EcoDry transformers manual (1LDE000005)

Self-Powered Feeder Protection REJ603 users and Transformer protection relay

technical manual (1MDB07208-YN)
SF6 Insulated Ring Main Unit and Compact Switchgear
Switchgear Installation and Operating Instructions
(6- 24 kV) (1VDD005976 GB)
Other

Main circuit diagram of the substation Whole substation

Main circuit diagrams of the inverters Whole substation

Part list Whole substation

Commissioning checklist Whole substation

PVS800 test report Inverters

Transformer test report Transformer

Safe ring routine test report Switchgear

Accessory documents Accessory

 Introduction to this manual 17

Terms and abbreviations

Term/Abbr. Explanation

AC Alternating current

CCF Construction of ABB Safering switchgear. See subsection Switchgear on page 22.

CCV Construction of ABB Safering switchgear. See subsection Switchgear on page 22.

DC Direct current

DeF Construction of ABB Safering switchgear. See subsection Switchgear on page 22.

DeV Construction of ABB Safering switchgear. See subsection Switchgear on page 22.

LV Low voltage (50 - 1000 V AC)

LVRT Low voltage ride-through

mpp Maximum power point. See also mppt.

mppt Maximum power point tracker. MPPT is a technique that solar inverters use to get the maxi-
mum possible power from solar panels.

MV Medium voltage (1 - 35 kV)

REJ603 Feeder protection relay by ABB

SF6 Sulfur hexafluoride. Gas type used in the Safering switchgear.

SWG Switchgear

THD Total harmonic distortion

TN-S Earthed network

18 Introduction to this manual
 Hardware description 19

3
Hardware description

Contents of this chapter

This chapter contains an introduction of the PVS800-MWS substation.

Overview
PVS800-MWS substation includes the equipment needed for the connection of a solar
power generator to the medium voltage power grid. The substation is built inside a
container. The main components are:
inverters which invert the direct current (DC) and voltage from the solar generator to
alternating current (AC) and voltage for the power grid. Inverters also control the
power flow, monitor and protect the power generator.
transformer which transforms low voltage from inverters to medium voltage for the
power grid.
switchgear which is the connection point to the power grid. It is also the main
protecting, switching, breaking and disconnecting equipment of the medium-voltage
side of the solar power plant.
20 Hardware description

Layout drawing

C
A B 7

1 3 4

2 9 5 9 8

Compartments:
A Switchgear compartment

B Transformer compartment

C Inverter compartment

Main components:
A 1 Switchgear

2 Lead-through holes for power grid cabling, and the terminal for the external earthing electrode
(in base plate, at end of switchgear compartment)

B 3 Transformer

C 4 Inverters

5 Lead-through holes for cabling from solar generator (on both sides of the substation)

6 Cooling air inlet

7 Cooling air outlets

8 Concrete base

9 Lifting eyes (four in total, two on both sides)

 Hardware description 21

Main circuit diagram

The diagram below shows the main circuit equipped with type CCV SafeRing switchgear
(option +F251) with auxiliary transformer (option +G344).

A B C

6
Aux. voltage
Local power
transformer
enclosure
(option +G344)

3
4
2 1

No. Description

A Switchgear compartment

B Transformer compartment

C Inverter compartment

1 DC input

2 Inverters

3 Transformer

4 Switchgear

5 Power grid (AC) connection (and to parallel substation (if any))

6 Auxiliary power supply

22 Hardware description

Switchgear
Substation is always equipped with ABB SafeRing switchgear. Type DeV is used as
standard but other types are also available:
DeV consists of two modules:
De is the grid-side module equipped with power cable terminals and an earthing
switch.
V is the transformer-side module equipped with the circuit breaker and an earthing
switch.
CCV consists of three modules:
C is the grid-side module with the grid cable terminals, and a disconnecting and
earthing switch.
The other C module is the grid connection point of the parallel-connected
substation.
V is the transformer-side module, equipped with the circuit breaker, and an
earthing switch.
DeF or CCF type switchgears are also possible. F stands for a switch-fuse
disconnector and an earthing switch. See the switchgear manual for more information.
The diagram below illustrates the alternative switchgear types with the types and the
option codes in a container delivery.

DeV CCV DeF CCF

Standard Option +F252 Option +F292 Option +F251 and +F292

Transformer
See the transformer manual for information on the transformer.

Inverter
See the inverter manuals for information on the inverters.
 Hardware description 23

Type designation label

The figure below shows the type designation label. The label contains the basic data of the
substation. It is located inside of the inverter compartment door.

IEC 62271-202
Serial nr: xxxxxxxxxxx
Type: PVS800-MWS-xxxxkW-zz +yyyy +yyyy

Prodyear: 2012-50
Order no: xxxxxxxxxx

AS ABB
ESTONIA

Item Description

IEC 62271-202 High-voltage switchgear and controlgear Part 202: High-voltage/low-voltage

prefabricated substation

Serial nr Serial number. Each substation has a unique serial number.

Type Type designation of the substation

xxxx = Size of the substation in kilowatts
zz= AC voltage of the container in kV
+yyyy = Option code. For example: +F251.
For more information, see section Type designation key on page 23.

Prodyear Production year and week

Order no Order number

Type designation key

Type designation describes the composition of the substation. The type designation is
visible on the type designation label which is attached to the substation. The complete type
designation is divided in sub codes:
The first 118 digits form the basic code. It describes the basic construction of the
substation. The fields in the basic code are separated by hyphens.
The option codes follow the basic code. Each option code starts with an identifying
letter (common for the whole product series), followed by descriptive digits. The option
codes are separated by plus signs.
24 Hardware description

The table below describes the fields of the basic code.

Digit no. Description
16 PVS800 product series
7 10 Construction. -MWS =
Container built, IP56 inverter compartment and IP23D SWG and transformer compartment,
concrete base, steel frame with corrosion class C4, double-staged air filtering for inverters.
Customer need to acquire and install: 3~ 400 V external control voltage, cable lead-through
entry and exits on the concrete base.
PVS800-57 central inverter with options +C176 doors with left hinges on left side (one inverter),
+G300 cabinet heater, +8H382 8 x fuse protected DC input connections, +Q951 Emergency
stop, +C175 Container construction
Safering 20 kV, 400 A, 16 kA/3s, DeV, with REJ603 protection relay, with cable bushings
interface C (400 bolted), 630 A
Vacuum coil cast dry type transformer DTE 1000 A8D (for 1000kW) and DTE 1250 A8D (for
1250kW), with winding temperature monitoring device
11 17 Size
-1000kW = 1000 kW
-1250kW = 1250 kW
18 20 Voltage rating
- 20 = 20 kV
- 6.6 = 6.6 kV (option)
- 11 = 11 kV (option)

The table below describes the option codes.

Code Description
Medium voltage switchgear options
F251 MV switchgear for ring connected networks. Safering CCx module instead of De.
F292 MV Fuse protected for Transformer. Safering xxF (fuse) module instead of xxV (circuit breaker)
(REJ 603 relay will be removed).
Main transformer options
F271 Grounding terminals to main transformer. 25 mm grounding terminals on MV busbars of main
transformer.
F293 High efficiency transformer. ABB Resibloc Basic.
Container options
G396 Auxiliary power supply voltage 3~173 V AC (100 V AC phase voltage)
G413 UPS support for auxiliary power (needed in LVRT)
G414 Installation rack for external components including 230 V power supply (e.g monitoring system)
G344 6 kVA auxiliary power transformer supplied from main AC side (no additional aux power supply
needed)
1H357 Cable lead trough system cover set 1. Includes HSI-150 system convers for DC, auxiliary, control
and 1 phase MV cables.
2H357 Cable lead trough system cover set 2. Includes HSI-150 system convers for DC, auxiliary, control
and 3 phase MV cables.
Container specialities
P902 Customized (see the project-specific documentation)
P926 Extended warranty 24/30 months for switchgear transformer and container (excluding Inverter).
P927 Extended warranty 36/42 months for switchgear, transformer and container (excluding Inverter)
 Storing, lifting and transporting 25

4
Storing, lifting and transporting

Contents of this chapter

This chapter contains instructions on storing, lifting and transporting the PVS800-MWS
substation.

Storing
To avoid any condensation inside the substation, store it indoor in a dry (heated)
warehouse. If that is not possible, supply and switch on the internal heaters to keep
the inside temperature above the temperature outside.
Place the substation on a solid, flat, dry, and vegetation-free ground. The ground must
support the substation evenly from below, ie, there must be no twisting or stress.
Place the substation on wooden support beams. Locate the beams under the lifting
points and at the middle.
Protect the interior of the substation from rain water and dust. At the minimum, cover
the air inlet and outlet gratings.
26 Storing, lifting and transporting

Lifting
Obey these instructions and the additional information given in section Lifting drawing on
page 63:
Protect the corners of the substation against shock.
Lift the substation from the lifting eyes (a). Use ring clutches TPA-R1 10.0.
Protect concrete base and substation with wooden support below the ring clutches
during lifting (b).
Use long enough spreaders (c) to avoid damage to the substation. The lifting slings
may not scratch the walls.
Adjust the lengths of the lifting slings so that the substation does not tilt during the
lifting.

WARNING! Ignoring the following instructions can cause physical injury or death,
or damage to the equipment:

Use only authorized lifting equipment and personnel.

Prevent anybody getting under the load.
Do not stand on the roof while fastening the lifting slings or while lifting.
Do not throw slings or hooks onto the roof.

a
 Storing, lifting and transporting 27

Transporting
Obey these instructions and the additional information given in section Dimensions, layout,
transportation details on page 60:
Protect the substation with wooden corners, plastic film, etc. The substation is
delivered unpacked from the factory as standard.
Protect the interior of the substation from rain water and dust. At the minimum, cover
the air inlet and outlet gratings (a).
Lay the substation directly on the transportation chassis to prevent sliding and to keep
the height as low as possible. We recommend to use friction enhancement mats
(rubber) below the substation. The maximum thickness of the mat is 2 cm.
Fasten the substation firmly onto the chassis with heavy-duty transport straps. Fasten
the straps to the lifting eyes (b) with ring clutches of type TPA-R1 10.0. Alternative
fastening points (c) are on the short sides of the substation: there are Rd36 threaded
holes in which you can install suitable anchors bolts.

Warning!
Transport the substation on an open heavy-duty chassis. Do not use a closed-top
trailer. The substation always moves somewhat during the transportation, and it
might get scratched to the walls of the trailer.
Keep the transportation height as low as possible. Do not use wooden beams below the
substation during transportation. Make sure that the total height of the transportation is not
above the maximum allowed height for the planned route.
Do not throw hooks over the roof.

c b
28 Storing, lifting and transporting
 Mechanical installation 29

5
Mechanical installation

Contents of this chapter

This chapter contains the instructions for selecting the location, and constructing the
foundation for the PVS800-MWS substation. These instructions do not substitute the local
regulations which you must obey always.

General guidelines
Place the substation higher than the surroundings
Place the substation a little higher than the surroundings to prevent corrosion caused by
surface water collecting against the substation.
Tilt the surface of the surrounding ground min. 3 cm per meter. This makes sure that
there is a proper flow of the surface water away from the substation.
Height of the concrete base is 39 cm. Bury it mostly into the ground but do not allow
the ground level to reach the metal walls. The concrete base must be about 8 cm
visible.
Consider the local conditions such as frost, rain (humidity) and drought.
30 Mechanical installation

Construct a sturdy foundation for the substation

The substation is heavy. Pay attention to the proper planning and constructing of the
foundation. Improper foundation may cause settling of the substation, difficulties to open
the doors, etc.
Make a deep enough hole for the foundation. Always dig into frost proof depth and drain
the hole. If possible, connect the foundation hole to the general drainage network or lead
the draining pipes to a well-drained terrain where the water does not cause harm.
Construct proper support for the substation:
On a solid sandy soil, gravel is usually enough. See subsection Foundation option 1
Supporting the substation with gravel below.
On a normal soil (solid, non-sandy), construct two concrete support beams under the
substation. See subsection Foundation option 2 Supporting the substation with
concrete beams below.
On a difficult soil (non-sandy, non-solid), construct concrete support pipes under the
substation. See subsection Foundation option 3 Supporting the substation with
concrete pipes below.
Fill the foundation hole with gravel according to the normal construction practices. Use a
glass fiber cloth to prevent mixing of fill gravel with the surrounding soil. Start the filling
with crushed stone or coarse gravel, and continue with finer material. Compress the filling
in layers. Use fine gravel (size 2 - 5 mm) for the surface layer. Smooth and compress the
surface.

Layers of gravel: Constructing the foundation

from coarse to fine
 Mechanical installation 31

Construct an earthing electrode

Construct an earthing electrode for the substation according to the local regulations. Lead
the connection wire of the electrode to the position from where it will be easy to connect it
to the earthing terminal of the substation. The earthing terminal is located on the concrete
base beside the lead through holes of the power grid cable. See section Earthing
(grounding) the substation on page 36 for the minimum requirements for the electrode.

Finalize the surroundings

Construct two rows of 500 500 mm concrete tiles at the substations service sides. They
will form a dry standing place for the personnel during service and prevent removal of
gravel.
Do not plant trees near the substation. If bushes will be planted, ensure that the planting
compost base is at least one meter from the substation housing, and that the fully-grown
bushes will not prevent maintenance access to the substation. Ensure also that the
plantation does not discharge dust or seeds that could hinder the cooling air flow.

Foundation option 1 Supporting the substation with

gravel
Support the substation with a gravel foundation when placing it on a solid and sandy soil.
Build the foundation as instructed in the section General guidelines above.
1000 mm
80 mm

30 mm

Note:
Tilt the surface of the surrounding ground min. 3 cm per meter.
Leave the concrete base 8 cm visible.
Consider the local conditions such as frost, rain (humidity) and drought.
32 Mechanical installation

Foundation option 2 Supporting the substation with

concrete beams
Support the substation with concrete beams when placing it on a normal soil (solid, non-
sandy) as follows:
1. Build the foundation as instructed in the section General guidelines above.
2. Cast two concrete support beams under the long sides of the substation.
Width: min. 200 mm. Depth: min. 500 mm or into frost free depth.
3. Level the top of the beams horizontally and with the surface of the ground.

1000 mm
80 mm

30 mm
min. 200 mm
2330 mm

min. 6830 mm

Note:
Tilt the surface of the surrounding ground min. 3 cm per meter.
Leave the concrete base 8 cm visible.
Consider the local conditions such as frost, rain (humidity) and drought.
 Mechanical installation 33

Foundation option 3 Supporting the substation with

concrete pipes
Support the substation with concrete pipes when placing it on a difficult soil (non-sandy,
non-solid) as follows:
1. Acquire the concrete support pipes.
Number: min. 6, Diameter: min. 150 200 mm. Length: min. 1100 mm. This vary
depending on the case. Use as long pipes as necessary.
2. Drill holes for the support pipes.
3. Put the pipes on place, and level them vertically.
4. Fill the bottom of the holes outside the pipes with concrete (1/3 of the whole depth).
5. Fill the top (rest 2/3) of the holes outside the pipes with soil. Compress as you fill.
6. Fill the pipes with concrete.

1000 mm
80 mm

30 mm
150 200 400
min. 1100 mm
min. 370 mm

2330 mm

Note:
Tilt the surface of the surrounding ground min. 3 cm per meter.
Leave the concrete base 8 cm visible.
Consider the local conditions such as frost, rain (humidity) and drought.
34 Mechanical installation

Placing the substation on the foundation

1. Measure the level of the foundation and the tilting of the surface of the surrounding
ground around the foundation. Make sure that you obey the rules in section Place the
substation higher than the surroundings on page 29. Do not place substation too low!
Adding gravel around a substation which you place too high, is much easier than
reinstalling the substation.
2. Measure the straightness of the foundation. Maximum tilting of the foundation surface
below the substation is 0.1 degrees.
3. Lift the substation on the foundation. Obey the instructions in section Lifting on
page 26.
4. After you put the substation on the foundation, measure again the height and tilting of
the substation, and the tilting of the surface of the surrounding ground around the
substation. Make sure that you obey the rules given in step no. 2 above and in section
Place the substation higher than the surroundings on page 29.
 Electrical installation 35

6
Electrical installation

Contents of this chapter

This chapter contains general instructions for earthing, and cabling of the PVS800-MWS
substation. The instructions do not substitute the local regulations which must always be
obeyed.

WARNING! Only an authorized electrician is allowed to install the cabling to the

substation. Follow the safety instructions. See chapter Safety instructions on
page 9, and the local safety regulations. If ignored, physical injury or death may
follow, or damage may occur to the equipment.

Routing the cables

Route the input DC power cables, AC power cables and control cables in separate paths.
Minimum distance between the control cables and DC (or AC) power cables is 500 mm
when run in parallel.
Do not install the control cables in the same cable trenches with DC cables.
Where control cables must cross power cables, ensure they are arranged at an angle as
near to 90 degrees as possible.
Use separate cable lead-through holes for different cable types.
Do not run extra cables through the substation.

Locations of the cable entries

See the chapter Drawings for the location of the cable entries.
36 Electrical installation

Earthing (grounding) the substation

Always construct an earthing electrode for the substation. Follow the local regulations. At
the minimum, the electrode must meet these requirements:
wire size: min. 16 mm2 Cu, 35 mm2 Al or 50 mm2 steel
depth: 50 to 80 cm from the surface of the soil
route: round the substation, distance 1 m from the outer wall
Connect the earthing electrode to the terminal located at the base of the substation beside
the power grid cable lead-through holes. Terminal type is HEA-M12/70 by Hauff Technik.
Use joint lubricant to protect the connection point against corrosion. Tightening torque
(M12 bolt) is 50 Nm.

Protective earthing (grounding) inside the substation

The protective earth (PE) terminals or frames of all main components inside the substation
have been connected to the main PE busbar at the factory. On the installation site:
Ensure the continuity of all internal PE connections by measuring the conductivity
between each protective earth terminal and the main PE busbar of the substation.
Earth the shields, armors and protective conductors of all incoming cabling to the
appropriate earthing terminals of the substation.
The diagram below shows the factory-installed internal PE connections inside the
substation, and the connection point of the external grounding electrode.

Rev B
 Electrical installation 37

Measuring the insulation resistances

Insulation resistance of the components and the internal cabling have been measured at
the factory. Do not retest. Do the following tests on field:
Test the external cabling before connecting it to the station.
Test the transformer and its cabling both from the primary and secondary side:
Primary side: Ensure that the disconnecting switch at the transformer side of the
switchgear is open but not in earthed position. Measure the insulation resistance
between the earth and each phase conductor of the transformer cable
Secondary side: Ensure that the AC disconnecting switches [Q1] are open in both
inverters units [PVS1] and [PVS2]. Measure the insulation resistance between the
earth and each phase conductor of the transformer cable.
Measuring voltage (Utest) and minimum resistance (Rmin) values are:
In medium voltage side Utest = 5000 V and Rmin= 1 Mohm per each 1 kV of the grid
voltage. Example: For a 20 kV system, the resistance is 20 Mohm.
In low voltage side Utest = 500 V and Rmin = 2 Mohm.

Connecting the cabling from the solar generator to the

inverters
See PVS800-57 hardware manual (3AUA0000053689 [English]) and the wiring diagrams
delivered with the unit.
1. Dismantle the covers of the cable lead-through holes.
2. Dig suitable cable trenches and protect the cables according to the local requirements
Use pipes, ducts, etc.
3. Lead the cables inside the substation and construct a tight cable lead-through. The
holes are equipped with Hauff HSI 150 K/70 lead-through elements as standard.
Compatible cable pipe adapters, sleeving, etc. sealing accessories are available from
Hauff Technik (http://www.hauff-technik.com).
4. Connect the cables to the appropriate terminals in the inverters. Tighten the
connection to torque specified in the inverter manual.
5. Fill the cable trenches and seal the cable lead-through as instructed in section
Finalizing the installation on page 39.
38 Electrical installation

Connecting the control cabling

See section Connecting the cabling from the solar generator to the inverters above. Follow
the same principle when connecting the control cables.
Connect the cables to appropriate terminals. See the connection diagrams delivered with
the substation.

Connecting the power grid cabling to the switchgear

See the switchgear manual and the wiring diagrams delivered with the unit.
1. Dismantle the covers of the cable lead-through holes.
2. Dig suitable cable trenches and protect the cables according to the local requirements
Use pipes, ducts, etc.
3. Lead the cables inside the substation and construct a tight cable lead-through. The
holes are equipped with Hauff HSI 150 K/70 lead-through elements as standard.
Compatible cable pipe adapters, sleeving, etc. sealing accessories are available from
Hauff Technik (http://www.hauff-technik.com).
4. Terminate the cables according to cable manufacturers instructions and connect the
cables to the switchgear. The standard cable terminations installed in the switchgear
are shown in the figure below.
5. Fill the cable trenches and seal the cable lead-through as instructed in section
Finalizing the installation on page 39.

Standard cable termination

Interface C, 400 series
Bolted type, M16 2 metric threads
 Finalizing and checking the installation 39

7
Finalizing and checking the
installation

Contents of this chapter

This chapter instructs in finalizing and checking the installation of the PVS800-MWS
substation.

WARNING! Only an authorized electrician is allowed to finalize and check the

installation. Follow the safety instructions. See chapter Safety instructions on
page 9, and the local safety regulations. If ignored, physical injury or death may
follow, or damage may occur to the equipment.

Finalizing the installation

Clean the substation of all dirt.
Repair any damage caused to the exterior painting during the transport or installation. See
section Checking and repairing the painted surfaces on page 52.
If you have not yet sealed the lead-through holes by no means (such as suitable lead-
through elements by Hauff Technik), cover the cable lead-through with sand and sprinkle a
handful of cement over the sand. In a few days the cement is hardened with the moisture
content of the sand, and it forms a firm barrier against small animals and plants.
40 Finalizing and checking the installation

Landscaping the substation

The suitability of the substation to its environment can be improved by planting bushes
around the substation.
Do not plant trees near the substation. If bushes will be planted, ensure that the planting
compost base is at least one meter from the substation housing, and that the fully-grown
bushes will not prevent maintenance access to the substation. Ensure also that the
plantation does not discharge dust or seeds that could hinder the cooling air flow.

Checking the installation

Item

Check all mechanical operating functions by operating them twice.

Check the earthing (grounding) of the substation and its components against the earthing
(grounding) schematic. Pull the earthing wires at the terminals to ensure that the connections are
tight.

Remove all foreign objects such as loose screws, nuts or tools from all compartments. They can
cause a short-circuit faults.

If there is sand or dirt inside the inverter, transformer or switchgear compartments, clean them. See
chapter Maintenance.

Check the main circuit clearance distances, cable terminations and connections against the main
circuit diagram. Check also that the connections have been tightened.

If there is a measuring cubicle in the switchgear, check that the instrument transformer ratios are
correct.

Check that all necessary warning labels have been attached to the substation.

Check that the insulation resistances of the external power cables have been measured.

Perform the installation checks detailed in the device specific manuals. See subsection Related
documents on page 16 for a list of manuals.

Carry out the inspection procedures required by the respective authorities.

 Start-up 41

8
Start-up

Contents of this chapter

This chapter instructs in the start-up of the PVS800-MWS substation.

WARNING! Only an authorized electrician is allowed to start-up the substation.

Follow the safety instructions. See chapter Safety instructions on page 9, and the
local safety regulations. If ignored, physical injury or death may follow, or damage
may occur to the equipment.

Tools needed
Computer with Drive window PC tool installed (for the inverter diagnostics and
settings)
Multimeter
Current injection device (for the testing of the protection relay of the switchgear)
Insulation resistance measurement device. See section Measuring the insulation
resistances on page 37 for the measuring voltages and resistance values.
42 Start-up

Start-up tasks
Task Additional information

Pre-checking the switchgear (voltage not connected)

Check the SF6 tank gas level from meter.

Operate all devices once. SF6 Insulated Ring Main Unit and Compact
Switchgear Installation and Operating
Instructions (6- 24 kV) (1VDD005976 GB)

Check the settings of protection relay are Tune the settings according to local utility grid
according to the factory test report. and the transformer type in use. Follow the
instructions in the product manual of the relay.

Protection relay REJ603: Check the condition of Self-Powered Feeder Protection REJ603 users
current transformers with multimeter. and technical manual (1MDB07208-YN).

Protection relay REJ603: Test the relay tripping. Current injection test described in the manual.

Pre-checking the transformer (voltage not connected)

Perform the transformer pre-checking routines. Instructions manual for dry-type transformers
(1LES100001-YB) or EcoDry transformers
manual (1LDE000005)

Check the insulation resistance of the transformer Measuring the insulation resistances on page 37
and its cabling if they have not been done on site
recently.

Pre-checking the inverters (voltage not connected)

Perform the inverter commissioning tasks/checks PVS800-57 hardware manual
to be done before the power-up. (3AUA0000053689 [English]) and PVS800
central inverters firmware manual
(3AUA0000058422 [English]).

Connecting the substation to the solar power generator and commissioning the inverters
Measure the DC supply voltage level at each input
terminal of inverter [PVS1].

Close the DC disconnector [Q2] of the first inverter

[PVS1].

Perform the inverter commissioning tasks/checks PVS800-57 hardware manual

that can be done with only the DC supply (3AUA0000053689 [English]) and PVS800
connected. central inverters firmware manual
(3AUA0000058422 [English]).

Repeat the above commissioning tasks for the

second inverter [PVS2].

Simulate transformer faults (unpowered) and

ensure that the inverters detect the fault indications
and trip.

Connecting the substation to the power grid

Check that AC disconnectors [Q1] of both inverters
[PVS1] and [PVS1]) are open.

Ensure that all checkings required by the local Consult the local power grid owner.
power grid owner have been done.
 Start-up 43

Task Additional information

Turn the earthing switch at the grid-side of the

switchgear to not earthed position.

Ask the power grid owner to connect the substation Only authorized personnel is allowed to perform
to the power grid. the connection.
Wait unit the substation has been connected to the
power grid before proceeding.

Turn the disconnecting switch at the grid side of

the switchgear to closed position.

Turn the earthing switch at the transformer side of

the switchgear to not earthed position.

Turn the disconnecting switch at the transformer

side of the switchgear to closed position.

Close the main breaker of the transformer.

Check that the voltage level on the low voltage Transformer monitoring relay and AC busbars of
side of the transformer is correct. Adjust the the inverters.
transformer tap settings if needed.

Run the transformer with no load for several hours If the ambient temperature is:
before proceeding to the tasks under the 10 C or above, run 3 hours.
subsection Connecting the inverters to AC supply.
below 10 C, run 6 hours.

Observe the transformer for any malfunction.

Monitor the temperature, check for audible
changes etc.

Connecting the inverters to AC supply

Close the AC disconnector [Q1] of the first inverter
[PVS1] to be commissioned.

Perform the rest of the inverter commissioning See PVS800-57 hardware manual
tasks (if any). (3AUA0000053689 [English]).

Close the AC disconnector [Q1] of the second

inverter [PVS2] to be commissioned.

Repeat the commissioning tasks (if any) for the

second inverter.
44 Start-up
 Maintenance 45

9
Maintenance

Contents of this chapter

This chapter contains the maintenance intervals table, and related maintenance
instructions.
The symbols in square brackets, for example [U1], refer to the device designations used in
the circuit diagrams.

General
The recommended maintenance intervals and component replacements are based on
specified operational and environmental conditions. ABB recommends annual inspections
to ensure the highest reliability and optimum performance. Consult your local ABB Service
representative for more details on the maintenance.

WARNING! Only an authorized electrician is allowed to service the substation.

Follow the safety instructions starting from page 9, and the local safety
regulations. If ignored, physical injury or death may follow, or damage may occur
to the equipment.
46 Maintenance

Maintenance intervals
The table below lists the routine maintenance intervals recommended by ABB.
Maintenance task Interval Instructions

Cleaning the inverter Every 2 years See section Cleaning the inverter
compartment (First check after commission) compartment on page 47.

Replacing intake air filters on the Every 2 years See section Replacing the intake
wall and on the door of inverter (yearly check) air filters of the inverter
compartment compartment on page 47.

Replacing stirrer fan in the Every 10 years See section Replacing the stirrer
inverter compartment (yearly check) fan in the inverter compartment
on page 48.

Replacing UPS battery (option Every 5 years See section Replacing the UPS
+G413) in the inverter battery (option +G413) in the
compartment inverter compartment on page
48.

Cleaning intake air filter on the Every 2 years See section Cleaning the intake
door of transformer compartment (yearly check) air filters on the doors of
transformer compartment on
page 49.

Replacing intake air filter on the Every 5 years See section Replacing the intake
door of transformer compartment (yearly check) air filters on the doors of
transformer compartment on
page 50.

Cleaning transformer and Every 5 years See section Cleaning the

switchgear compartment (First check after commission, transformer and switchgear
then yearly check) compartments on page 49.

Replacing cooling fan in the Every 10 years See section Replacing the
switchgear compartment (yearly check) cooling fan in the switchgear
compartment on page 51.

General condition check, Every year See section Checking and

checking and repairing painted (First check after commission) repairing the painted surfaces on
surfaces page 52.

General condition check, Every 5 years See section Checking and

checking grounding bar cleaning the grounding bars and
points on page 54.

General condition check, After 2 years of installation, and See the dimensional layout
checking tilting of solar station after 10 years of installation. drawing for reference
(1VPD000012X0036).

The main components of the substation have their own routine maintenance schedules in
addition to the tasks listed in the table above. See the appropriate manuals listed in
section Related documents on page 16.
 Maintenance 47

Inverter compartment
Cleaning the inverter compartment

WARNING! Do the steps given in section Safety instructions for the inverter
compartment on page 13. Ignoring the instructions can cause physical injury or
death, or damage to the equipment.

1. Clean the floor plates with a vacuum cleaner.

2. Remove floor plates and check the cleanliness of the concrete base.
3. Clean the base with a vacuum cleaner.
4. Put the floor plates back.
5. Clean outer surfaces of inverters [PVS1, PVS2], control cabinets/enclosures and the
compartment heater [E1] with a vacuum cleaner.

Replacing the intake air filters of the inverter compartment

1. Stop the inverters [PVS1, PVS2], and the stirrer fan [U1] located on the ceiling of the
compartment. The fan is supplied from the Local power enclosure [EAB].
2. Loosen the screws on the filter supports on 3 sides.
3. Remove one filter support on each filter frame.
4. Replace the air filters. Before you add a new filter, check and clean the sand boxes
and door interior with a vacuum cleaner.
5. Install the filter support frames back and tighten the screws.
6. Check and clean the sand boxes and door interiors with a vacuum cleaner.
48 Maintenance

Replacing the stirrer fan in the inverter compartment

The stirrer fan [U1] is located on the ceiling of the compartment. The circuit breaker
supplying the fan is in the Local power enclosure [EAB].
1. Switch off the circuit breaker supplying the stirrer fan [U1]. Prevent the accidental
switch-on of the breaker during the maintenance procedure.
2. Check by measuring that no voltage is connected to the fan.
3. Replace the fan.
4. Power up the fan and check that it is blowing the air to right direction, ie, towards the
door of the compartment.

Replacing the UPS battery (option +G413) in the inverter

compartment

WARNING! Do the steps given in section Safety instructions for the inverter
compartment on page 13. Ignoring the instructions can cause physical injury or
death, or damage to the equipment.

1. Switch off the main switch of the Local power enclosure [EAB] to cut the supply for the
inverters and their UPS battery (option +G413).
2. Open the door of the auxiliary control cubicle of the inverter cabinet. The UPS battery
(option +G413) is located on the floor.
3. Ensure by measuring that no voltage is connected to the USP battery.
4. Replace the battery by following its users guide.
 Maintenance 49

Transformer and switchgear compartments

Cleaning the transformer and switchgear compartments

WARNING! Do the steps given in section Safety instructions for the switchgear
compartment on page 11 and Safety instructions for the transformer compartment
on page 12. Use safety glasses and respiratory protector if using compressed air.
Ignoring the instructions can cause physical injury or death, or damage to the equipment.

1. Ensure that the transformer has cooled down before you proceed.
2. Use a vacuum cleaner to clean floor, doors, and interior metal beams on concrete
base. If necessary use duster or pressured air as help around corners with no proper
access with vacuum cleaner.
3. Clean the surface of the transformer with a duster. In case of lot of dust, use
compressed air for cleaning the transformer.
4. Clean the insulators of the transformer with ethanol.

Cleaning the intake air filters on the doors of transformer

compartment

WARNING! Do the steps given in section Safety instructions for the

transformer compartment on page 12. Use safety glasses and respiratory
protector while using compressed air. Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

1. Blow compressed air gently from inside to outside through the filter until the dust will
come off.
50 Maintenance

Replacing the intake air filters on the doors of transformer

compartment

WARNING! Do the steps given in section Safety instructions for the transformer
compartment on page 12. Ignoring the instructions can cause physical injury or
death, or damage to the equipment.

1. Remove the metal frames of the filters.

2. Replace the filters.
3. Install the metal frames.
 Maintenance 51

Replacing the cooling fan in the switchgear compartment

WARNING! Do the steps given in section Safety instructions for the switchgear
compartment on page 11. Ignoring the instructions can cause physical injury or
death, or damage to the equipment.

1. Switch off the circuit breaker supplying power supply for the cooling fan in the
switchgear compartment. The circuit breaker is located in the local power enclosure
[EAB] in the inverter compartment. Prevent the accidental switch-on of the breaker
during the maintenance procedure.
2. Check by measuring that no voltage is connected to the fan.
3. Replace the fan and power it up.
4. Check that fan blows air to right direction. Use temperature controller of the
transformer [ETT] to start the fan temporarily (enable the fan relay test). The fan
rotates to right direction if air flows out from the switchgear compartment. Change the
direction of the fan when necessary.
52 Maintenance

Substation
Checking and repairing the painted surfaces
Materials
Sand paper
Cleaning towels and liquids
Primer below paint on rusted or/and scratched surfaces: Hempel zinc primer 16490 or
Wrth Rost Stop 0890 191 (or similar)
Finishing paint: Hempel Hempathane HS 55610 two-component polyurethane paint
(or similar)
Paint colors: See Paint colors on page 56.
Note! Obey the instructions given by the material manufacturers.

Procedure

WARNING! Do the steps given in section Safety instructions for the switchgear
compartment on page 11. Ignoring the instructions can cause physical injury or
death, or damage to the equipment.

If there is lost finishing paint but no damage to the metal beneath or no rust visible:
1. Clean the damaged area with suitable detergent followed by a water clean.
2. Let the surface dry completely and keep it clean.
3. Cover the damaged area with the finishing paint.
If there are scratches and bare metal or rust visible (see a in figure below):
1. Remove rust gently with sand paper.
2. Clean the damaged area and its surrounding.
3. Coat the damaged area with primer. Let it dry thoroughly.
4. Add top paint on the damaged area.

Lost paint but no damage beneath it Scratch to the metal and rust

a
 Maintenance 53

Checking and repairing the non-painted, zinc coated surfaces

Materials
Sand paper
Cleaning towels and liquids
Zinc coating on non painted surfaces: Wrth Zinc 300 0892 200 with brush or Zinc
Spray Perfect 0893 114 113 (or similar)
Note! Obey the instructions given by the material manufacturers.

Procedure

WARNING! Do the steps given in section Safety instructions for the switchgear
compartment on page 11. Ignoring the instructions can cause physical injury or
death, or damage to the equipment.

Pay special attention on doors and lower parts of the walls. Those areas have potentially
corrosive elements like dust and humidity.
1. If there is rust, remove the rust gently with sand paper.
2. Clean the damaged area and its surrounding.
3. Coat the damaged area with zinc coat. Wrth Zinc 300 preferred due to thicker coat.
On larger areas Wrth Zinc Spray Perfect can be used to speed up the work and to do
even better looking surface.
54 Maintenance

Checking and cleaning the grounding bars and points

Materials
Steel wool
Ensto SR1 joint compound (or similar)
42839 Wrth Protective Wax Spray (or similar).

Procedure

WARNING! Do the steps given in section Safety instructions for the switchgear
compartment on page 11 and Safety instructions for the transformer compartment
on page 12. Ignoring the instructions can cause physical injury or death, or
damage to the equipment.

1. Check the condition of grounding bar and grounding cables in switchgear

compartment. In case of visible corrosion, remove the cables and remove the
corrosion with steel wool. Apply then joint compound onto the grounding bar and cable
terminals.
2. Change the spring lock washers. Tighten the cables with nominal torque values
(Torque for a M12 bolt is 50 Nm).
3. In case there was a of lot of corrosion, apply protective wax spray on the grounding
bar and the cable terminals.
 Technical data 55

10
Technical data

Contents of this chapter

This chapter contains the technical data of the PVS800-MWS substation.

Technical data
PVS800-MWS-1000kW-20 PVS800-MWS-1250kW-20
Central inverter type PVS800-57-500kW-A PVS800-57-630kW-B
Ratings: Input data (DC)
Temp 40 C 40 C
PPV, MAX [kWp] 2 600 2 750
UDC, mpp [V DC] 450825 525825
UDC, max [V DC] 1000 1000
IDC, max [A DC] 2 1145 2 1230
UPV, ripple [%] <3 <3
Number of inputs 2 8 (+/-) 2 8 (+/-)
Number of mppt trackers 2 2
Ratings: Output data (AC)
Temp 40 C 40 C
PAC, N [kW] 1000 1250
IAC, N [A AC] 28.9 36.1
UAC, N [V AC] 20000 20000
fN [Hz] 50/60 50/60
Harmonic distortion [%] <3 <3
56 Technical data

PVS800-MWS-1000kW-20 PVS800-MWS-1250kW-20
Auxiliary power
Allowed electrical system type 400 V 3-phase TN-S 400 V 3-phase TN-S
Terminal size (per conductor) [mm2] 16 16
Aux power, running (without options) [W] <1140 <1140
Aux power, standby (without options)) [W] <150 <150
Additional max. heating power [W] 2200 2200
Efficiency
hmax [%] 97.8 97.8
heuro [%] 97.1 97.3
(at minimum mppt DC voltage, standard transformer,
no auxiliary power included)
Cooling
Inverter compartment cooling air flow [m3/h] 6720 6720
Inverter cooling method Forced air cooling Forced air cooling
Transformer and switchgear cooling method Natural cooling Natural cooling
Dimensions and weight
Width / Height / Depth [mm] 6930 / 3070 / 2430 6930 / 3070 / 2430
Weight [tons] approx. 20 approx. 21
Power cable lead-through and
terminals
Switchgear compartment See Drawings on page 59. See Drawings on page 59.
Inverter compartment See Drawings on page 59 See Drawings on page 59
and the inverter hardware and the inverter hardware
manual. manual.
Cable lead-through type HSI-150 system covers. HSI-150 system covers.
See Dimensions, layout, See Dimensions, layout,
transportation details on transportation details on
page 60. page 60.
Paint colors
Walls RAL 7035 (light beige, RAL 7035 (light beige,
semigloss) semigloss)
Roof RAL 7012 RAL 7012
Degree of protection and ambient
conditions
Degree of protection IP54 (inverter compart.) / IP54 (inverter compart.) /
IP23d (other compart.) IP23d (other compart.)
Ambient temperature range (max.) [C] -1540 (50) no frost -1540 (50) no frost
allowed. See Derating allowed. See Derating
below. below.
Relative humidity [%] 15 to 95%, no condensation 15 to 95%, no condensation
allowed allowed
Highest altitude (max.) [m] 1000 (2000). See Derating 1000 (2000). See Derating
below. below.
Corrosivity category of environment C4 (EN ISO 12944-2) C4 (EN ISO 12944-2)
Fuses and protection relays
Main circuit AC protection relay REJ603-CT2 REJ603-CT2
Inverter DC fuses (option+8H382) See inverter manual See inverter manual
 Technical data 57

PVS800-MWS-1000kW-20 PVS800-MWS-1250kW-20
Applicable standards
Sub-station IEC 62271-202 High-voltage/low-voltage prefabricated
substation
Transformer IEC 60076-11 Power Transformers, DIN EN 60076-11,
VDE 0532-76-11
Switchgear IEC 60694 Common specifications for high-voltage
switchgear and controlgear standards,
IEC 62271-100 High-voltage switchgear and controlgear -
Part 100: High-voltage alternating-current circuit-s,
IEC 62271-102 High-voltage switchgear and controlgear -
Part 102: Alternating current disconnectors and earthing
switches,
IEC 62271-105 High-voltage switchgear and controlgear -
Part 105: Alternating current switch-fuse combinations,
IEC 62271-200 High-voltage switchgear and controlgear -
Part 200: A.C. metal-enclosed switchgear and controlgear
for rated voltages above 1 kV and up to and including 52
kV,
IEC 60265-1 High-voltage switches- Part 1: Switches for
rated voltages above 1 kV and less than 52 kV,
IEC 60529 Degrees of protection provided by enclosures
(IP code)
Inverter See PVS800-57 hardware manual (3AUA0000053689
[English]).
Product compliance
Safety and EMC CE conformity According to LV and EMC directives
Grid compliance According to country requirements
Cable lead-through data See chapter Drawings.

Derating
In altitude from 1000 to 2000 m (3300 to 6600 ft) above sea level, the derating is 1% for every 100 m (328 ft).
If the installation site is above 2000 m (6600 ft) above sea level, contact your ABB distributor or office for
further information.
In temperature range +40 C (+104 F) to +50 C (+122 F), the nominal output current must be derated 2% for
every additional 1 C (1.8 F). The output current is calculated by multiplying the nominal current by the
derating factor.
Example: If the ambient temperature is +50 C (+122 F), the derating factor is 100% - 2%/C 10 C = 80%
or 0.80. The actual output current is then 0.80 Nominal output current.

110
Derated output current

100
(% nominal value)

90

80

70
25 30 35 40 45 50

Temperature C
58 Technical data
 Drawings 59

11
Drawings

Contents of this chapter

This chapter contains the additional drawings of the PVS800-MWS substation.
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 Max 60

Min 3200mm
Max 4200mm
Lifting drawing

Length 7152mm Length 7021mm

[284.6in] [276.4in]
276,0in
7010mm

1165mm
45,9in

3412mm
134,3in

33,5in
850mm
33,5in
850mm

Note:
- The center of gravity of the lifted station shall be exactly below the hook of the crane. This is done by adjusting the individual
lengths of the lifting chains accordingly. Total weight: 20000kg*
- Lifting equipment Frimeda Transport Anchor System from HALFEN is to be used. Valid only with ABB DTE 1000 or DTE 1250
The lifting equipment is fastened to the lifting eyes by means of ring clutches type TPA-R1 10.0 valid only with ABB DTE 1250 transformer installed
*transformers
- In order to avoid any unnecessary stress and twisting of the enclosure it is very important that all four lifting chains
engage the load at the same time.
Name / Material Length Width Consumpt Item no. Weight
- The length of the lifting chains is to be adjusted so that the substation does not tilt more than 3 during lifting. Surface Scale Basic tolerances
Control Department
- Lifting equipment shall match, and fulfil needs for total lifting weight. 1:25 ISO 2768-m
Drawn Responsible Department Title
29.11.2011 ROION LAKE
POWER IT, CSS
Approved Revision New Department
7.22 x 2114 Country Code
- Important: Ensure personnel safety during lifting by using authorized lifting equipment and preventing anybody getting MWS Lifting Instruction
Drawings 63

EE
Changed Pages
under the load. Draw. no / Doc. no.
1
Page no.
ABB Technology Ltd 1VPD000008 1
We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. Copyright 2005 ABB
 64 Drawings

Location of cable entries

Ground cable MV cables

2 pcs Hauff Technik HSI 150)

DC cables for inverter 1

( 3 pcs Hauff Technik HSI 150)

Auxiliary power supply inlet/outlet

cables
(1 pcs Hauff Technik HSI 150)

DC cables for inverter 2

( 3 pcs Hauff Technik HSI 150)

Control cables (1 pcs Hauff Technik HSI 150)

Note: The control cables must not be installed into same pit
with DC cables. Follow minimum distances between control
and DC cables stated in the PVS 800-57 Harware Manual
(Chapter 5).
Further information
For more information on ABB products and services for solar applications, navigate to
www.abb.com/solar.
 Contact us

www.abb.com/solar

3AUA0000092830 Rev B (EN) 2012-11-23